Method Statement for MICC Cables Installation

method statement for MICC cables

Purpose

This method statement for MICC cables describes the installation as per project specifications, regulations in a safe manner to an approved and controlled methodology.

The Job Hazard analysis in the appendix identifies the hazards and the safe systems of work to be followed when conducting the activity.

Scope

The scope of this document includes, but is not limited to the following:
a) Methodology for MICC Cables Installation
b) Tools & equipment used
c) Inspection and Test Plans
d) HSE Assessment & Job Hazard Assessment

Definitions/Abbreviations

HSE Health, Safety and Environment
QA/QC Quality Assurance/ Quality Control
ITP Inspection and Test Plan
WIR Work Inspection Request
PTW Permit To Work
BS British Standard
MICC Mineral Insulated Copper Cable

Tools and Equipment

The following tools and equipment items have been identified for the installation of wiring accessories and general power system related works:
a. Hand Tools Box (Spanner set, cutting players, screwdriver set, hammer, hacksaw frame & flat file, cleaning brush, spirit levels)
b. Measuring tape
c. Drilling Machine
d. A-Type Ladder
e. Mobile Type Scaffolding with wheel safety lock
f. Labeling printer
g. Pot
h. Pot Seal
i. Gland
j. Potting compound
k. Pot crimper
l. Stub sleeve
m. Plier
n. Crimper
o. Joistripper
p. Ringing tool

Sequence of Works

The following are the step by step procedures for the installation of light fixtures & wiring devices and accessories
Prior to installation, it will be ensured that:

a. All relevant documentation such as (Approved Shop drawings, Checklist and Approved Method Statement for Installation of MICC cables, etc.) and the material applicable to a particular section of work will be Checked by the Site engineer prior to the commencement of work ensuring that these are of the correct type as reviewed by the Engineer
b. Before commencement of installation, Material inspection will be carried out prior to being withdrawn from the storage area i.e. quantity, physical damage and brand/make.
c. Before the beginning of the installation, it will be ensured that the approved valid permit to work (PTW) is available on site.
d. Engineer in charge will ensure that approval and standard tools and tackles are available to carry out the work.
e. Safe access to work areas will be provided and will be approved by the competent safety person prior to commencement of works if applicable.
f. Check the work area tidy and remove flammable materials if any and a safe environment will be ensured.
g. Where the risk assessment identifies high-risk works a permit to work will be obtained from the safety department.
h. Competent manpower will be employed to carry out the installation work.
i. Prior to installation, It will be ensured that all the civil works are completed.
j. Necessary Civil clearance will be obtained (if applicable) prior to the start of installation.

Material Transport

a. MICC Cables and other related accessories will be handled and transported and unloaded at site strictly as per manufacturers instruction.
b. After delivery, Items will be inspected for any transport both internal and external components casing damage, in compliance with project specification & materials submittal.
c. Approved shop drawings will be posted at the workplace for site reference used and installation works.

Delivery and Storage:

a. Upon material delivery, storage and equipment handling will be kept as directed in a neat with safety precautionary measures according to the manufacturer’s recommendation and in accordance with the HSE Plan.
b. Deliveries will be inspected and handled at the site area according to the given instructed requirements.
c. Mechanical handling will be considered prior to manual handling.
d. When materials arrive at the site will be inspected randomly and ensure that the materials are as per approved material submittals.
e. Any discrepancies, damage, and etc. found to the materials will be notified and reported to QA/QC Engineer and Project Engineer for further action.
f. All the material will be inspected and approved by Engineer prior to dispatch to the site and commencement of works.
g. Materials found not suitable for site use will be removed from the site immediately.
h. While unloading, shifting, and storage, it will be ensured that there are no damages.
i. All delivered materials will be inspected on arrival at the site.
j. All materials will be free from any defects or damages and foreign materials that will result in the inability to install the materials and subsequent deterioration.

Handling

a. All materials will be delivered to the site by truck/trailer.
b. All incoming MICC cable drums will be off-loaded on the nearest point of cable pulling start point.
c. When the drum reaches designated areas, the cable drum will be unloaded to the proper cable jack directly for easy cable pulling operation.
d. After unloading of cable drums, it will be ensured that there is no damage that occurred during transportation & lifting.
e. Any discrepancies, damage, and etc found to the materials will be notified and reported to QA/QC Engineer.
f. Materials found not suitable for site use will be removed from the site immediately and moved to the quarantine zone.
g. On receiving materials at the site, a material inspection request will be raised for Engineer approval.
h. All the materials will be as per approved material submittal.
i. No materials will be permitted to enter the work location without prior inspection and approval.

Methodology

Installation of MICC Cables

MICC Power cable is a high conductivity copper conductor embedded in highly compacted magnesium oxide insulation with a robust, ductile copper sheath. MICC Cables are mainly installed in Substations for electrical lighting and small power systems.

Laying of MICC Cable

a. All cables will be laid as per approved shop drawings. Instrument and control cables will not be grouped with power cables.
b. Minimum bending radius of the cable will be checked prior to cable pulling to avoid exceeding the bending limit.
c. Cable identification tag will be made available for cable in advance and also after glanding.
d. It will be ensured that the cable ladder/cable trays are free from any sharp edges and are having sufficient spaces for installation.
e. Visual inspections are performed to ensure there are no sharp edges or burrs that could damage the MICC cables during installation.
f. Before removing the hoist, the direction of the arrow on the drum will be checked and will be in the same direction as the pull.
g. The necessary cable roller will be placed in the cable passage and the cable winch and pulling grips will be connected to the cable.
h. Proper coordination and communication between the workforce will be ensured.
i. When unrolling cable, a plastic or plywood sheet will be provided and laid in-ground for cable protection and will avoid any scratches and damages to the cable’s outer sheath insulation.
j. Cable roller guides will be placed under the cable during pulling over longer distances and standoff rollers for acute bends and will ensure that the cable is pulled with minimum effort and cable outer jacket is free at scouring lines
k. It will be ensured that the cable will not be allowed to twist or rotate about its longitudinal axis during the pulling process.
l. It will be ensured that the cable will not be bent during installation, either permanently or temporarily to a radius less than the allowed minimum bending radius allowed by the manufacturer.
m. The cables will be spaced in accordance with the approved shop drawings and tied to the ladder/tray using approved cleats and or cable ties for both horizontal and vertical run. MICC cables shall be installed on cable trays and secured to backstraps fixed to the side of the trench. Such cables shall be saddled to this cable tray at intervals of not more than 500mm as per project specifications.
n. Cables will be installed from terminal point to terminal point and straight through joints will not be made unless approved. Where a run of MICC cable is of a length that exceeds the maximum which can be manufactured, a through joint of a pattern agreed with the Engineer will be permitted as per requirements.

Installation of MICC Cables in Substations

a. Before the start of works, it will be ensured that the civil works are completed.
b. It will be ensured that all accessories, tools, and equipment are available before the start of work.
c. All the responsible precautions to prevent damage to the cable from severe blows with sharp instruments and pulling over sharp objects are taken.
d. The cable will not be pulled around corners that have sharp edges, such as corners in cable trays, or other obstructions.
e. The cables will be completely uncoiled (if needed) or removed from the reel and laid out in a straight run with the end to be pulled closest to the entry point into the support system.
f. The cable will be pulled by hand through the desired routing.
g. When changing the direction from a horizontal to a vertical pull, sheaves or pulleys will be used to guide the cable around the bend.
h. The surface run cables will be fixed with saddles at intervals of not more than 500mm as per project specification.
i. Conduct an insulation test on the cable and record the result.
j. Cable will be identified at both ends for proper identification of cable. The marker sign will be the same as the feeder designation in the cable schedule.
k. Where cable passes through a fire barrier approved fire-stopping material will be provided as recommended by the Engineer.

Termination of MICC Cable:

a. Cable glands will be brass compression glands and comply with the relevant part of BS 6121, except for MICC cables, which shall comply with BS 6207 Part 2.
b. Cut the cable off the square. This will be done with a small hacksaw, a ringing tool, or sharp cable shears.
c. Start the stripped cable by turning the joistripper clockwise down the cable.
d. When the cable is stripped to the desired length, lightly grip the cable with the pliers. Run the joistripper up to the pliers. This will give a nice clean square cut.
e. Put the gland top, olive, and gland bottom of the cable. Do not tighten it up yet.
f. Screw the pot in the cable until the sheath of the cable is flush with the bottom of the pot. Be very careful not to twist the cable while screwing on the pot. Then pull the wires slightly apart and test the wires with an insulation tester.
g. Slightly overfill the pot with potting compound. It is ensured not to touch the compound which could cause the pot not properly insulated the pot.
h. Slide the pot seal into place, making sure the wires are not twisted.
i. Insert the pot assembly into the pot crimper, it will be ensured that three prongs of crimper are between where the wires come through the seal.
j. Crimp the pot.
k. Sleeve the wire into stub sleeving and carry out another insulation test to ensure cables are free of fault. Also need to do the continuity test.
l. Slide the gland into place.
m. It will be ensured that the technicians wash their hands after the installation. Magnesium oxide is not good for health.
n. After the cable ends are terminated with the permanent seal, the cable should be subjected to IR (Insulation Resistance) Test.

Personnel

Project Manager

a. Project Manager (MEP) will be responsible to manage, executing, complete and handover the construction activities within approved budgets and resources in compliance with project requirements as specified in project specifications. He will be overall in charge of implementing the Method Statement in accordance with QA/QC and HSE requirements.
b. Responsible for controlling the project’s entire activities & for the overall coordination with the d. consultant/client.
c. Ensure that adequate welfare facilities and equipment are provided to the project to avoid injury, health impairment, or damage & to ensure providing quality works within the planned time scale.
d. All responsibilities stated in the Project’s Quality Assurance Plan.

Construction Manager

a. Organize the site so that work is carried out to the required specifications with minimum risk to men, equipment, and materials.
b. Coordination with different functions with the project.
c. Expediting area of concern to achieve project schedule.
d. Adhere to the project-specific quality management program and HSE requirements.
e. Delivering the overall works in a safe and timely manner, ensuring conformance with the
approved design. Leading the team of engineers and surveyors, guiding them in the delivery
of the works. Acquire, allocate and maintain resources.

QA/QC Manager

a. Responsible for the work entire quality assurance, quality control & inspection programs
b. Produce all quality-related documents & reports necessary as requested by the Owner/Consultant/Engineer.
c. Provide written procedures & coordinate in formalizing the Method Statements with the Project Manager/ Construction Managers/Site Engineers to describe the job-specific work for each stage/activity.
d. All responsibilities stated in the Project’s Quality Assurance Plan.

QA/QC Engineer

a. Responsible for the work entire Quality Assurance/Quality Control activities & inspection programs.
b. Produce all quality-related documents & necessary quality reports as requested.
c. Provide written procedures & to coordinate in formalizing the Method Statements with the Construction Manager/Site Engineers to describe the job-specific work for each stage/activity
d. Make sure that all the works mentioned in this method statement will carry out in approved shop drawing and as per the project specification.
e. Make sure WIR for all these activities are raised and approved by the consultant and record those documents for testing, commissioning, and handing over the procedure.

Safety Manager

a. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and procedures.
b. Ensures safe work method of stated in method statement and risk assessment is fully implemented during activity.
c. Responsible for controlling HSE personnel for effective monitoring of work.
d. Oversee site safety orientations/inductions, toolbox talks, safety training certifications, job site inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
e. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety Engineers / Officers) as well as property damages immediately. Produce investigative reports and summaries to senior management.

Safety Officer

a. Provide advice and coordination in line with the project HSE Plan, legislation, and standards to workgroups as required/directed.
b. Input into the preparation and maintenance risk register at the project level which will form the basis of risk management on the project.
c. Monitoring and reporting compliance with the Project HSE Plan.
d. Conducting regular HSE inspections and participating in HSE audits.
e. Reporting as required, HSE incidents, including near-miss events, injuries, and any other HSE issues.
f. Regularly attending toolbox and other HSE meetings
g. Ensures that the worksite has been examined, and all precautions specified to be taken in the PTW before work commences have in fact been taken
h. Will ensure that the works are examined on completion of the works and the “Permit To Work” is correctly closed.

Site Engineer
a. Adheres to the Project-specific method statements, procedures, inspection programs & HSE instructions to get the activities performed to client satisfaction with full coordination with the HSE & quality personnel.
b. Responsible to ensure that correct drawings, materials, tools, and equipment are provided site.
c. Liaising with sub-contractors, supervisors, planners, quantity surveyors send the general workforce involved in the project.
d. Responsible for planning the work and efficiently organizing the plan and site facilities in order to meet agreed deadlines.
e. Site engineer is responsible to coordinate with QA/QC Team engineers/ inspectors, and handover daily site progress works reports/highlighted drawings & presenting during inspection/site visit with QA/QC Inspectors & consultant/client.

Foreman

a. Performed the activities that were instructed by the Supervisor/Engineer at the site and follow the safety procedures to make it safe for his workers.
b. In charge to lead the work execution send the focal point in coordinating with the site Supervisor/Engineer related to overall site activity, materials, tools, and equipment.

Technician

a. Carry out Installation work as per the concerned foreman’s instructions with all the safety requirements.
b. The workforce to attend daily toolbox talks, morning task brief briefs prior to starting any works EHS (Environment Health Standard) plans and policies.

Workforce

a. Carry out their work in such a way that they don’t create for themselves or any other person risk to health safety, and don’t impact the environment to the maximum extent possible or affect the quality of work.

Quality Control

The Inspection and Test Plan (ITP) for this Method Statement summarizes various characteristics to be checked. The concerned Site Engineer or Site Supervisor will be responsible to ensure compliance for these operations and the site QA/QC Engineer will carry out quality control checks and report the inspection results.

Quality Records

Quality records will be provided as identified in the ITP and maintained as per ISO 9001/2015 Standard form of records, quality checklists and QA/QC reports requirements are defined in the Inspection and Test Plan.